Three-dimensionally printed cloth molding and method

ABSTRACT

According to the present invention, a three-dimensional cloth molding which has superior feel and durability, and a method for three-dimensionally molding cloth which offers low production cost and high productivity are provided. Cloth layer 85 having a print pattern, foam 87, and fabric 88 having one surface on which a plastic film is laminated are locationally placed on an elastic sheet 86. While foam 87 is still in a viscoelastic fluid state, cloth 85, foam 87, fabric 88, and elastic sheet 86 are integrally pressurizingly compressed for a predetermined time duration by upper metal mold 80 and lower metal mold 82. Thereby, foam 87 is fixedly adhered to the back surface of cloth 85 to support a print pattern of the cloth, and is three-dimensionally molded so as to conform to the profile of the print pattern. The plastic film of fabric 88 is almost fixedly adhered to the surface of foam body 87, but only the peripheral edge portion of the fabric 88 is thermally adhered by additionally heating to the back surface of the cloth. As a result, foam body 87 is completely sealed between the cloth and the fabric.

FIELD OF TECHNOLOGY

The present invention relates generally to a method for forming athree-dimensional print on the surface of cloth made of various texturesso as to conform to the shape of a printed pattern; more particularly,the present invention relates to a method for three-dimensionallyforming prints or marks of various characters applied to various typesof shirts, jeans, and jackets.

BACKGROUND ART

With respect to prior art of a method for three-dimensionally shapingthe cloth, for example, U.S. Pat. No. 5,296,182 or U.S. Pat. No.5,389,318 disclose the method for integrally shaping the cloth usingreaction process of liquid foaming mixtures such as polyurethane foam.The method is comprised of pressurizingly integrally molding thepolyurethane foam and the cloth by means of an upper metal mold andlower metal mold which have a desired three-dimensional configurationbetween when gasification reactions of the liquid foaming mixture hasfinished until the mixture substantially solidifies. As the foamcompletely goes into the solid state by being left in situ for a while,a three-dimensionally printed cloth of final desired pattern isfinished. This conventional method for three-dimensionally molding thecloth has been widely applied to handbags or apparel items such asshirts, jeans, or jackets.

But these conventional methods have some drawbacks.

One of these disadvantages is that if a three-dimensional print is putonto the cloth such as a shirt by the conventional method, the foam bodywhich is adhered to the back surface of the cloth directly contacts withuser's skin, so that it causes a very uncomfortable feel to the user.Another disadvantage of the conventional method is that since the foamportion of the shirt molded by the conventional method is exposed tooutside air, the surface of the foam body is quickly degraded byrepeated laundering or by the ultraviolet rays from the sun.

Even if the back surface of the foam body portion is covered with fibermaterials as described in the above references, such fiber materials arenot enough to prevent sweat or rain from freely penetrating into thefoam, so that the cloth discolors or the foam body portion gets heavierbecause of absorbing moisture.

Further, since the method of the above reference, wherein a liquidfoaming mixture is deposited directly onto a non-adhesive polyethylenefilm, then they are integrally molded, and thereafter the polyethylenefilm is peeled away, uses polyethylene film which has poorexpansion-and-contraction properties, it is necessary to replace thepolyethylene film each time, which results in lower working efficiencyand greater production cost.

It is, therefore, a object of the present invention to provide athree-dimensionally printed cloth molding and method that prevents thefoam body from directly contacting with user's skin, that does notdetract from the feel, and that keeps sweat or moisture from beingabsorbed by the foam body.

It is another object of the present invention to provide athree-dimensionally printed cloth molding and method that prevents thesurface of the foam body from being degraded by repeated laundering orby the ultraviolet rays from the sun, thereby to improve its normaldurability.

It is still another object of the present invention to provide athree-dimensionally printed cloth molding and method that reducesproduction costs and improves throughput.

DISCLOSURE OF THE INVENTION

These and other objects of the invention, which will be apparent in viewof the following detailed specification, are accomplished by meanshereinafter described and claimed.

One aspect of the invention of three-dimensional cloth molding shaped byintegrally pressurizingly compressing a cloth and foam comprises:

a cloth layer having a print pattern on the surface, and moldedthree-dimensionally so as to conform to the profile shape of said printpattern;

a foam body layer which is fixedly adhered to the entire back surfaceregion of the print pattern of said cloth layer and supports thethree-dimensional shape of said print pattern; and,

a fabric layer having one surface on which a plastic film is laminated,wherein after integral pressurizing compression is implemented, only theperipheral edge of said fabric layer is thermally adhered to the clothin the periphery region around the back surface of said foam body so asto cover substantially the entire back surface of said foam body layer.

Another aspect of three-dimensional cloth molding shaped by integrallypressurizingly compressing a cloth, foam and fabric comprises:

a cloth layer having a print pattern on the front surface, and moldedthree-dimensionally so as to conform to the profile shape of said printpattern;

a foam body layer which is fixedly adhered to the entire back surfaceregion of the print pattern of said cloth layer and supports thethree-dimensional shape of said print pattern; and,

a fabric layer having one surface on which a plastic film is laminated,wherein at the back surface region of said foam body the plastic filmside of said fabric layer is fixedly adhered to the entire back surfaceof the foam body so as to conform to the profile shape of the backsurface of said foam body, at the peripheral region of said foam bodythe plastic film side of the peripheral edge region of said fabric layeris thermally adhered to the cloth of the peripheral edge region aroundthe back surface of said foam body layer.

In aforementioned three-dimensional cloth molding, said foam body ispreferably made of a polyurethane or polyurea foam.

In aforementioned three-dimensional cloth molding, said fabric layer mayconsist of either woven fabric, knitted fabric, or nonwoven fabric.

In aforementioned three-dimensional cloth molding, said plastic film maybe made from nylon, polyester, or polypropylene each consisting ofmoisture-nonpermeable thermoplastic resins, and is 10 μm to 1 mm thick.

On the other hand, one aspect of the method for three-dimensionallymolding a printed cloth corresponding to a print pattern of the clothsurface, comprises the steps of:

placing a fabric layer having one surface on which a plastic film islaminated onto a flat elastic sheet with said plastic film surfaceupward;

depositing liquid foaming mixture onto said fabric layer so as toconform to desired profile;

opposing a back surface of said printed cloth to said fabric layer sothat the print pattern profile of the cloth conforms to the profile ofthe liquid foaming mixture;

integrally pressurizingly compressing said printed cloth, the foam, thefabric layer, and the elastic sheet by means of both an upper metal moldwhose inner surface corresponds to the shape of three-dimensionalsurface of the print pattern and a lower metal mold whose inner surfacecorresponds to the shape of the three-dimensional back surface of theprint pattern, when predetermined time duration is past after the foamis deposited while the foam being still under viscoelastic fluid state;and,

holding integral compression for a while to allow the foam to transit tosolid state and fixedly adhering the plastic film side of the fabriclayer to the back surface of the foam.

Another aspect of method for three-dimensionally molding a printed clothcorresponding to a print pattern of the cloth surface, comprises thesteps of:

depositing liquid foaming mixture onto a flat elastic sheet so as toconform to desired profile;

opposing a back surface of said printed cloth to said flat elastic sheetso that the print pattern profile of the cloth conforms to the profileof the liquid foaming mixture;

integrally pressurizingly compressing said printed cloth, the foam, andthe elastic sheet by means of both an upper metal mold whose innersurface corresponds to the shape of three-dimensional surface of theprint pattern and a lower metal mold whose inner surface corresponds tothe shape of the three-dimensional back surface of the print pattern,when a predetermined time duration is past after the foam is depositedwhile the foam is still in a viscoelastic fluid state;

transiting the foam to solid state as retaining desired shape which isformed by both said upper metal mold and said lower metal mold byholding integral compression for predetermined time duration; and,

thermally adhering the peripheral edge of the fabric having one surfaceon which a plastic film is laminated to the cloth of the peripheralregion around back surface of said foam body so that said fabricsubstantially cover the entire back surface of said foam body.

In aforementioned method for three-dimensionally molding a printedcloth, said elastic sheet may be made of natural rubber or siliconerubber.

In aforementioned method for three-dimensionally molding a printedcloth, liquid foaming mixture of said foam is deposited in the desiredshape by means of a dispensing system or a spraying system.

In aforementioned method for three-dimensionally molding a printedcloth, the method may comprise the further step of:

preheating raw materials of said liquid foaming mixture to the range of60 to 80° C. before it is deposited.

In aforementioned method for three-dimensionally molding a printedcloth, at the step of integrally pressurizingly compressing, thepredetermined time duration between deposition of said liquid foamingmixture and pressurizing compression may be 30 to 50 seconds.

In aforementioned method for three-dimensionally molding a printedcloth, the predetermined time duration for holding the integralcompression may be 30 seconds to 3 minutes.

In aforementioned method for three-dimensionally molding a printedcloth, the method may comprise the further step of:

thermally adhering the peripheral edge of the fabric having one surfaceon which a plastic film is laminated to the cloth of peripheral edgeregion around the back surface of said foam body.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a shirt having a three-dimensional printaccording to the present invention.

FIG. 2A is a cross-sectional view and

FIG. 2B is a partially enlarged view of the first embodiment of athree-dimensionally printed cloth molding according to the presentinvention.

FIG. 3A is a cross-sectional view and

FIG. 3B is a partially enlarged view of the second embodiment of athree-dimensionally printed cloth molding according to the presentinvention.

FIG. 4 is a top plan view and

FIG. 5 is a side view of a foam depositing jig used in the method forthe three-dimensionally molding of a printed cloth according to thepresent invention.

FIG. 6 is a top plan view and

FIG. 7 is a side view of a masking jig used in the method for thethree-dimensionally molding of a printed cloth according to the presentinvention.

FIG. 8 is a top plan view and

FIG. 9 is a side view of a cloth placing jig used in the method for thethree-dimensionally molding of a printed cloth according to the presentinvention.

FIG. 10 is a top plan view and

FIG. 11 is a side view of a cloth locating jig used in the method forthe three-dimensionally molding of a printed cloth according to thepresent invention.

FIG. 12 shows the integral compression by both the upper metal mold andlower metal mold used in the method for the three-dimensionally moldingof a printed cloth according to the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

The present invention is described below with reference to the drawings.

FIG. 1 shows a T-shirt in which is embodied a three-dimensional printaccording to the present invention. The A--A cross-sectional view isshown in FIGS. 2A and 3A.

FIG. 2A is cross-sectional view of the first embodiment of thethree-dimensionally printed cloth molding according to the presentinvention, and FIG. 2B is a partially enlarged view of FIG. 2A.Three-dimensionally printed cloth molding 20 according to the presentinvention comprises, cloth layer 22 having a print pattern on itssurface which is three-dimensionally molded so as to conform to aprofile of the print pattern, foam layer 23 which is molded integrallywith the cloth layer 22 to support the three-dimensional profile of theprint pattern, and fabric layer 25 having one surface on which a plasticfilm 24 is laminated. Foam layer 23 is made of solidified polyurethaneor foaming resin of polyurea-foam, which is pressure molded by a methodthat will be hereinafter described in detail. The thickness of the foamlayer 23 is determined by clearance between the upper metal mold and thelower metal mold, preferably, it is about 1 mm. Plastic film 24 is madeof a thermoplastic material, such as nylon or polyester, that is notpermeable to moisture and 10 μm to 1 mm (preferably 50 μm) thick. Fabriclayer 25 is made of a fiber material such as woven fabric, knittedfabric, or nonwoven fabric, and has a circumference that is radiallylarger than that of the print of the cloth by about 20 mm to 30 mm.Fabric layer 25 is arranged so as to substantially cover the entire backsurface of foam layer 23. Preferably, fabric layer 25 is fixed to thecloth by holding the peripheral region which is inward by 10 mm to 20 mmfrom the edge of the fabric and heating up to about 200° C. for about 20seconds, in order to thermally adhere the plastic film which islaminated on the fabric to the cloth of the peripheral region around theback surface of the foam body. The fabric layer 25 may also be fixed byan adhesive.

FIG. 3A is a cross-sectional view of the second embodiment of athree-dimensionally printed cloth molding according to the presentinvention, and FIG. 3B is a partially enlarged view of FIG. 3A.Three-dimensionally printed cloth molding 30 according to the presentinvention comprises, cloth layer 32 having a print pattern on thesurface and molded three-dimensionally so as to conform to a profile ofthe print pattern, foam body layer 33 which is fixedly adhered to theback surface region of the print pattern of the cloth and supports thethree-dimensional shape of the print pattern, and fabric layer 35 havingone surface on which a plastic film 34 is laminated. The raw materialand size of each of the elements are the same as those of embodiment 1.A different point from embodiment 1 is that fabric layer 35 having onesurface on which a plastic film 34 is laminated is fixedly adhered overback surface of the foam body so as to substantially cover the entireback surface of foam layer 33 to conform to the profile of the printpattern. In addition, the peripheral region of fabric layer 35 isthermally adhered to the cloth of the peripheral region around the backsurface of the foam body similar to fabric layer 25 described by FIG. 2.The fabric layer 35 is integrally shaped with the cloth and foam by themethod according to the present invention which will be hereinafterdescribed in detail.

The method for three-dimensionally molding a printed cloth according tothe invention is described. FIGS. 4 through 8 indicate the equipment andarrangement for shaping the three-dimensionally printed cloth accordingto the present invention. The first method according to the inventionfor three-dimensionally molding printed cloth comprises the steps of,placing a fabric layer having one surface on which a plastic film islaminated onto a flat elastic sheet with the plastic film surfaceupward, depositing a liquid foaming mixture onto the fabric layer so asto conform to a desired profile, opposing a back surface of printedcloth to the fabric layer so that the print pattern profile of the clothconforms to the profile of the liquid foaming mixture, integrallypressurizingly compressing the printed cloth, the foam, the fabriclayer, and the elastic sheet by means of both an upper metal mold whoseinner surface corresponds to the shape of three-dimensional surface ofthe print pattern and a lower metal mold whose inner surface correspondsto the shape of the three-dimensional back surface of the print patternwhen predetermined time duration is past after the foam is deposited,while the foam being still under viscoelastic fluid state, and holdingintegral compression for a while to allow the foam to transit to solidstate and fixedly adhering the plastic film side of the fabric layer tothe back surface of the foam.

FIGS. 4A and 5 are respectively the top and side view of the foamdepositing jig used in the first step of placing a fabric layer havingone surface on which a plastic film is laminated onto a flat elasticsheet with the plastic film surface upward, and in the second step ofdepositing a liquid foaming mixture onto the fabric layer so as toconform to a desired profile. The foam depositing jig 40 comprises acylindrical portion 46 and a flange portion 44 which extends outwardlyfrom one open end of the cylindrical portion. Flange portion 44 has atleast two reference holes 45, 45' such that at least two reference pins83, 83' provided on lower metal mold 82 shown in FIG. 12 engage into thereference holes 45, 45' thereby the foam depositing jig 40 is fixed. Onthe upper end surface of cylindrical portion 46 of the foam depositingjig 40, elastic sheet 41 which is a one of the features of the methodaccording to the present invention is stretched with uniform tension.The elastic sheet 41 is made from materials which have usefulcharacteristics with respect to expansion and contraction ability,restorability, and peelability of the foam. Preferably, the elasticsheet 41 is silicone rubber with 0.5 mm thickness. It may be comprisedof natural rubber or other synthetic rubber.

FIGS. 5(A) and (B) are respectively the top and side view of the maskingjig used in the second step of depositing a liquid foaming mixture ontothe fabric layer so as to conform to a desired profile. The masking jig50 comprises a masking board 51, which consists of an approximately2-mm-thick disk made from polyethylene resin having useful foamseparability from the metal mold, and a flange portion 53. At the centerof the masking board 51, opening 52, which is routed to correspond tothe profile of print pattern of the cloth, is provided. Reference pins54, 54' are provided under the flange portion 53 to engage intoreference holes 45, 45' of foam depositing jig 40 shown in FIG. 4.

According to the first method for three-dimensionally molding a cloth, afabric layer having one surface on which a plastic film is laminated isplaced onto an elastic sheet 41 of foam depositing jig 40 shown in FIG.4 with the plastic film upward. Preferably, the periphery of the fabriclayer is radially larger than the periphery of the print pattern byabout 25 mm. Next, masking jig 50 of FIG. 5 is mounted on the foamdepositing jig 40, and liquid foaming mixture is deposited with a sprayfrom above opening 52. The liquid foaming mixture is comprised of apolyurethane foam or polyurea foam which is a mixture of isocyanate(ISO), polyol (poly), other catalyst, and water. The mixture spraysystem is a well-known device for example the PSM80 by ISOTHERM Co. Ltd.In the mixture spray system, each of liquid raw materials isindependently preheated to 60-80° C. (preferably to 70° C.) and isstirred and mixed at high pressure in the mixing head. The resultingfoam atomized mixture is sprayed onto a target. The foam may also becoated on by a dispensing method. After the coating of the liquid foammixture is completed, masking jig 50 is quickly removed from foamdepositing jig 40. As a result, foam mixture layer 43 having a desiredprofile is formed on the fabric layer as shown in FIG. 4.

FIGS. 6 and 7 show respectively cloth placing jig 60 and cloth locatingdevice 70 used in the third step of opposing a back surface of printedcloth to the fabric layer so that the print pattern profile of the clothconforms to the profile of the liquid foaming mixture. FIGS. 8 and 9 arerespectively the top and side view of cloth placing jig 60. Clothplacing jig 60 comprises cylindrical portion 62 and flange portion 61which extends outwardly from one open end of the cylindrical portion 62.Upper open end 65 of cylindrical portion 62 is curled outward to preventthe cloth from catching on it. At least two reference holes 63, 63' areprovided on flange portion 61. As shown in FIG. 6, shirt 64 which isreversed is held to curled end 65 of cylindrical portion 62 by a rubberband with the print surface upward. It should be noted that the profileof the print pattern must conform to the profile of liquid foam andshape of inner surface of lower metal mold 82 of FIG. 8. This problem issolved by cloth locating device 70 which is shown in FIG. 7.

FIGS. 10 and 11 show respectively a top view and side view of locatingdevice 70. Locating device 70 comprises cover 71 and chamber 77. Thecover 71 comprises cylindrical portion 73 and flange portion 72. Theupper end surface of the cylindrical portion 73 is sealed bypolyethylene resin plate 79 having opening 74 whose profile conforms tothe profile of the print pattern. A lot of vent holes 75 are provided onthe inner side of opening 74. Reference pins 76, 76' are provided on theflange portion 72, so that the reference pins engage into referenceholes 63, 63' of cloth placing jig 60. Exhaust pump (not shown) isconnected to chamber 77 through outlet 78.

The third step of the method of the present invention, which iscomprised of opposing a back surface of printed cloth to the fabriclayer so that the print pattern profile of the cloth conforms to theprofile of the liquid foaming mixture, is carried out specifically asfollows, using the jigs and devices of FIGS. 6 and 7.

First, cloth placing jig 60 of FIG. 8 is mounted on locating device 70of FIG. 10 so that the reference pins are inserted into the referenceholes. Next, shirt 64 which is reversed is placed onto cloth placing jig60 with the print side upward. Following this step, the exhaust pump isactuated and chamber 77 is exhausted by the pump. The print portion ofthe shirt, because of little air permeability, is pulled due to ventholes 75 toward opening 74. In this situation, the operator can manuallyadjust the position of the shirt so that the profile of print of theshirt conforms to the periphery of the opening 74, and then he can fixthe shirt to curled end 65 with a rubber band to hold. Thus, both clothplacing jig 60 on which the shirt is locationally fixed in position andfoam depositing jig 40 on which liquid foam is coated are mounted onlower metal mold 82 of FIG. 12 so that the back surface of the printedcloth opposes the liquid foam.

FIG. 12 shows upper metal mold 80 and lower metal mold 82 used in thefourth step of integrally pressurizingly compressing according to thepresent invention. Upper metal mold 80 and lower metal mold 82 arepreferably made of aluminum, and concave surface 81 of the upper metalmold and convex surface 84 of the lower metal mold are respectivelyshaped so as to conform to the profile of the print pattern. Foamdepositing jig 40 of FIG. 4 and cloth placing jig 60 of FIG. 6 aremounted onto the lower metal mold 82 in order that reference pins 83,83' of the lower metal mold 82 engage into the reference holes of eachof the jigs.

It should be noted that it is important to determine the timing when thepolyurethane foam is pressurizingly compressed. As is well known in theart, the chemical reactions of the foam consist of gasification reactionand solidification reaction following it. If compression molding isimplemented before the foam gasification reaction has completed,unreacted foam may soak out of the surface of the shirt. On thecontrary, if compression molding is implemented after the solidificationreaction has completed, there arises a problem that the foam does notadhere to the back surface of the shirt. Therefore, the compressionmolding must be implemented carefully and speedily between the time whenthe gasification reaction has finished until the time when thesolidification reaction begins (generally called tack-free), that is,while the foam body is still in a viscoelastic fluid state. Byexperiment, it was found that the time of compression molding is when itis past 30 to 50 seconds from when the liquid foam is coated on,preferably it is when it is past 40 seconds from then. The rising heightdue to the expansion of the foam can be selected in the range of 5 mm to55 mm depending on the blend of the raw materials and the quantity ofthe foam deposited. According to the fourth step of the presentinvention, elastic sheet 86, fabric 88, liquid foam 87 which is underviscoelastic fluid state, and shirt 85 are integrally pressurizinglycompressed by concave surface 81 of upper metal mold 80 and convexsurface 84 of lower metal mold 82.

According to the fifth step of the present invention, the integralpressurizing compression is preferably implemented by applying a forceof 1256 kg (4 kg/cm2×200 mm diameter) for 30 seconds to 3 minutes.During this time, the foam transits to a solid state retaining the shapeof three-dimensional print pattern which is molded by upper metal mold80 and lower metal mold 82, and at the same time the plastic filmsurface of fabric 88 adheres to the back surface of the foam. Theaforementioned compression time can be reduced by heating the uppermetal mold and lower metal mold before compression molding. After thefoam has sufficiently solidified and the plastic film surface of thefabric has adhered fully to the back surface of the foam body, shirt 85is removed from the metal mold and is displaced onto an iron (not shown)by which the surface of the shirt is compressed and heated at about 40°C. and the back surface of the shirt is simultaneously compressed andheated at about 200° C. for about 20 seconds. Thereby, the plastic filmat the peripheral edge of the fabric 88 thermally adheres to clothportion along the circumference of the back surface of the foam body,and the entire foam is completely sealed between the back surface of theprinted cloth of the shirt and the plastic film surface of the fabric.

In the second method of the present invention, a foam is coated directlyonto an elastic sheet. The elastic sheet is the same as the elasticsheet 41, but silicone rubber which has better foam peelability ispreferable. The second method according to the present invention forthree-dimensionally molding printed cloth comprises, depositing a liquidfoaming mixture onto a flat elastic sheet so as to conform to a desiredprofile, opposing a back surface of printed cloth to the elastic sheetso that the print pattern profile of the cloth conforms to the profileof the liquid foaming mixture, integrally pressurizingly compressing theprinted cloth, the foam, and the elastic sheet by means of both an uppermetal mold whose inner surface corresponds to the shape ofthree-dimensional surface of the print pattern and a lower metal moldwhose inner surface corresponds to the shape of the three-dimensionalback surface of the print pattern while the foam is still underviscoelastic fluid state after gas reactions of the foam are completedand allowing the foam to transit to solid state at the same time,locating a fabric having one surface on which a plastic film islaminated so as to substantially cover the entire back surface ofcompressed foam and thermally adhering periphery portion of the fabricto the cloth of peripheral region around the back surface of the foambody. The jigs and devices used in the second method are the same asthose used in the first method. It is different from the first method inthat only the peripheral edge portion of the fabric having one surfaceon which a plastic film is laminated is thermally adhered to the clothof peripheral region around the back surface of the foam body afterintegral compression. The method of thermally adhering is the same asthat of the first method.

Thus, by three-dimensionally printed cloth molding according to thepresent invention, the foam body is never directly in contact with theuser's skin because it is completely sealed by a fabric having onesurface on which a plastic film is laminated.

Further, the feel is not impaired because the fabric is inserted betweenthe foam body and the skin, and sweat and moisture never seep into thefoam body because they are guarded by the plastic film.

Moreover, the deterioration of the surface of the foam body by repeatedlaundering or by ultraviolet rays from the sun is reduced because thefoam body is completely covered by the fabric, thereby the durability innormal use is improved.

On the other hand, in the method for three-dimensionally molding printedcloth according to the present invention, by using silicone rubber whichhas good expansion and contraction properties, good restorability, andgood peelability, it is possible not only to use it as a elastic sheetrepeatedly for many times, but also to deposit the foam directly ontothe silicone rubber, whereby production costs can be greatly reduced andthroughput can be improved as compared to conventional.

We claim:
 1. A three-dimensional cloth molding shaped by compressionmolding to integrally form a cloth and foam comprising:a cloth layerhaving a print pattern on the surface, and molded three-dimensionally soas to conform to the profile shape of said print pattern; a foam bodylayer which is fixedly adhered to the entire back surface region of saidcloth layer in the area of said print pattern and supports thethree-dimensional shape of said print pattern; and, a fabric layerhaving one surface on which a plastic film is laminated, wherein aftercompression molding is implemented only the peripheral edge of saidplastic film of said fabric layer is thermally adhered to said clothlayer around the back surface of said foam body layer so as to coversubstantially the entire back surface of said foam body layer.
 2. Athree-dimensional cloth molding as set forth in claim 1, wherein saidfoam body is made of a polyurethane or polyurea foam.
 3. Athree-dimensional cloth molding as set forth claim 1, wherein saidfabric layer consists of either woven fabric, knitted fabric, ornonwoven fabric.
 4. A three-dimensional cloth molding as set forth inclaim 1, wherein said plastic film is made from nylon, polyester, orpolypropylene each consisting of moisture-nonpermeable thermoplasticresins, and is 10 μm to 1 mm thick.
 5. A three-dimensional cloth moldingshaped by compression molding to integrally form a cloth, foam andfabric comprising:a cloth layer having a print pattern on the frontsurface, and molded three-dimensionally so as to conform to the profileshape of said print pattern; a foam body layer which is fixedly adheredto the entire back surface region of said cloth layer in the area ofsaid print pattern and supports the three-dimensional shape of saidprint pattern; and, a fabric layer having one surface on which a plasticfilm is laminated, wherein at the back surface region of said foam bodylayer said plastic film of said fabric layer is fixedly adhered to theentire back surface of said foam body layer so as to conform to theprofile shape of said back surface of said foam body layer and at theperipheral region of said foam body layer said plastic film at theperipheral edge region of said fabric layer is thermally adhered to saidcloth layer around the back surface of said foam body layer. 6.Three-dimensional cloth molding as set forth in claim 5, wherein saidfoam body is made of a polyurethane or polyurea foam. 7.Three-dimensional cloth molding as set forth in claim 5, wherein saidfabric layer is consisting of either woven fabric, knitted fabric, ornonwoven fabric.
 8. Three-dimensional cloth molding as set forth inclaim 5, wherein said plastic film is made from nylon, polyester, orpolypropylene each consisting of moisture-nonpermeable thermoplasticresins, and is 10 μm to 1 mm thick.
 9. A method for three-dimensionallymolding a printed cloth corresponding to a print pattern of the clothsurface, comprising the steps of:placing a fabric layer having onesurface on which a plastic film is laminated onto a flat elastic sheetwith said plastic film surface upward; depositing a liquid foamingmixture onto said fabric layer; opposing a back surface of the printedcloth to said fabric layer so that the print pattern profile of thecloth conforms to the profile of the liquid foaming mixture; compressionmolding the printed cloth, the foam, the fabric layer, and the elasticsheet by means of both an upper metal mold whose inner surfacecorresponds to the shape of a three-dimensional surface of the printpattern and a lower metal mold whose inner surface corresponds to theshape of a three-dimensional back surface of the print pattern at a timeafter the foam is deposited and while the foam is still in aviscoelastic fluid state; and, holding compression for a while to allowthe foam to transit to solid state and to fixedly adhere the plasticfilm side of the fabric layer to the back surface of the foam.
 10. Amethod for three-dimensionally molding a printed cloth corresponding toa print pattern of the cloth surface, as set forth in claim 9, whereinsaid elastic sheet is made of natural rubber or silicone rubber.
 11. Amethod for three-dimensionally molding a printed cloth corresponding toa print pattern of the cloth surface, as set forth in claim 9, whereinliquid foaming mixture of said foam is deposited in the desired shape bymeans of a dispensing system or a spraying system.
 12. A method forthree-dimensionally molding a printed cloth corresponding to a printpattern of the cloth surface, as set forth in claim 9, comprising thefurther step of:preheating raw materials of said liquid foaming mixtureto the range of 60 to 80° C. before being deposited.
 13. A method forthree-dimensionally molding a printed cloth corresponding to a printpattern of the cloth surface, as set forth in claim 9, wherein the timeduration for holding the integral compression is 30 seconds to 3minutes.
 14. A method for three-dimensionally molding a printed clothcorresponding to a print pattern of the cloth surface, as set forth inclaim 9, wherein at the step of compression molding, the time durationbetween deposition of said liquid foaming mixture and pressurizingcompression is 30 to 50 seconds.
 15. A method for three-dimensionallymolding a printed cloth corresponding to a print pattern of the clothsurface, as set forth in claim 9, comprising the further stepof:thermally adhering the peripheral edge of the fabric having onesurface on which a plastic film is laminated to the cloth in theperipheral edge region around the back surface of said foam body.
 16. Amethod for three-dimensionally molding a printed cloth corresponding toa print pattern of the cloth surface, comprising the steps of:depositinga liquid foaming mixture onto a flat elastic sheet; opposing a backsurface of the printed cloth to said flat elastic sheet so that theprint pattern profile of the cloth conforms to the profile of the liquidfoaming mixture; compression molding said printed cloth, the foam, andthe elastic sheet by means of both an upper metal mold whose innersurface corresponds to the shape of a three-dimensional surface of theprint pattern and a lower metal mold whose inner surface corresponds tothe shape of a three-dimensional back surface of the print pattern at atime after the foam is deposited and while the foam is still in aviscoelastic fluid state; transiting the foam to solid state byretaining the desired shape which is formed by both said upper metalmold and said lower metal mold by holding compression for a timeduration; and, thermally adhering the peripheral edge of the fabrichaving one surface on which a plastic film is laminated to the cloth ofthe peripheral region around the back surface of said foam body so thatsaid fabric substantially covers the entire back surface of said foambody.
 17. A method for three-dimensionally molding a printed clothcorresponding to a print pattern of the cloth surface, as set forth inclaim 16, wherein said elastic sheet is made of natural rubber orsilicone rubber.
 18. A method for three-dimensionally molding a printedcloth corresponding to a print pattern of the cloth surface, as setforth in claim 16, wherein liquid foaming mixture of said foam isdeposited in the desired shape by means of a dispensing system or aspraying system.
 19. A method for three-dimensionally molding a printedcloth corresponding to a print pattern of the cloth surface, as setforth in claim 16, comprising the further step of:preheating rawmaterials of said liquid foaming mixture to the range of 60 to 80° C.before it is deposited.
 20. A method for three-dimensionally molding aprinted cloth corresponding to a print pattern of the cloth surface, asset forth in claim 7, wherein at the compression molding, thepredetermined time duration between deposition of said liquid foamingmixture and pressurizing compression is 30 to 50 seconds.
 21. A methodfor three-dimensionally molding a printed cloth corresponding to a printpattern of the cloth surface, as set forth in claim 16, wherein thepredetermined time duration for holding the integral compression is 30seconds to 3 minutes.
 22. A three-dimensional cloth molding comprising,a cloth layer having a front surface with a print pattern thereon and aback surface, said cloth layer having a three-dimensional portionassociated with said print pattern, a foam layer having a front surfaceadhered to said back surface of said cloth layer in the area of saidprint pattern and providing a three-dimensional support to which saidcloth layer conforms, and a fabric layer having a plastic film laminatedon a front surface thereof, said plastic film covering said foam layerand having a peripheral edge thermally adhered to said back surface ofsaid cloth layer, whereby said foam layer is fully enclosed between saidcloth layer and said fabric layer.
 23. A three-dimensional cloth moldingaccording to claim 22, wherein said plastic film of said fabric layer isadhered to said foam layer.